Documente Academic
Documente Profesional
Documente Cultură
SECTION 31003
PAGE 1
1.0
GENERAL
1.1
DESCRIPTION
1.1.1
The quality assurance, inspection and testing procedure shall be complied with in
every respect unless otherwise stated agreed by the E.R.
1.2
WORK INCLUDED
1.2.1
1.2.2
1.2.3
Provide assistance and testing equipment for witnessed site inspection and tests.
1.2.4
Perform site tests and commissioning for all mechanical and electrical equipment.
1.3
SUBMITTALS
1.3.1
(2)
(3)
(4)
Quality Plan
1.3.2
For Inspection and testing, submit inspection and testing procedures, programme and
record sheets.
1.3.3
After completion of testing, submit test records, packaging, transportation and storage
instructions and methods.
1.3.4
1.3.5
1.4
QUALITY ASSURANCE
The Contract shall refer to the appropriate parts of ISO 9000 series as guidelines for
the implementation of the quality programmes.
2.0
3.0
EXECUTION
3.1
3.1.1
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Acceptance of the Contractor's quality assurance programme does not relieve the
Contractor's obligation to comply with the requirement of the Contract document. If
the programme is found to be ineffective or inadequate in providing for quality
assurance or control, then the Employer's Representative reserves the right to request
for necessary revisions of the programme.
3.1.3
3.1.4
(2)
(3)
(4)
Quality Plan
3.1.5
These documents shall be prepared by the Contractor for all items and services to be
supplied, after the Contract has been placed, but before commencement of
fabrication, and shall be subject to evaluation and acceptance by the Employer's
Representative before start of works.
3.1.5.1
3.1.5.2
(1)
Quality policy
(2)
(3)
(4)
(5)
Lines of communication
(6)
Customer relations
(7)
Laboratory facilities
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(2)
(3)
Product Checklist
(4)
(5)
(6)
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3.1.5.4
(7)
(8)
(9)
Pre-commissioning
(10)
Commissioning
(11)
Control of Non-conformances
(12)
Corrective Action
(13)
(14)
Records
(15)
Quality Audit
(16)
Personnel Training
(17)
Quality Plan
The Contractor shall be required to prepare manufacturing and construction/erection
quality plans for all equipment items and services. The quality plan shall also define
the involvement of the Employer's Representative in the inspection and test
programmes.
The Quality Plan shall incorporate as appropriate :
(1)
(2)
The charts shall indicate the requirement for quality control, inspection and test
beyond which manufacture shall not continue until the action required by the
requirement is met, and the documentation required is generated.
(3)
The control documents associated with each hold point, i.e. drawings, material
specification, Works Process Schedule (WPS), Process Quality Records
(PQR), quality control methods and procedures and acceptance Standards.
(4)
(5)
These documents shall detail the procedures and approvals with which the
process complies.
(6)
(7)
Reference to
procedures.
(8)
The Contractor shall submit his contractor's quality plans. The Contractor shall
determine and agree with the Employer's Representative the control to be
quality
assurance
procedures,
and
non-conformance
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(10)
3.2
REPAIR PROCEDURES
3.2.1
The Contractor shall prepare a Repair Procedure for Works and site based on the
specification requirements and approved Standards for mechanical equipment and
finishing and painting. The procedure shall take into account Site conditions, and be
detail enough to include, for example, equipment to be used, methods of repair,
acceptance/rejection criteria, inspections required, etc. The repair procedure shall
cover welding, painting, etc.
3.3
OTHER DOCUMENTS
3.3.1
The Contractor shall submit to the Employer's Representative one copy of other
relevant documents, such as manufacturer's instructions, technical papers, etc., where
such documents are being referred to in the documents.
3.4
3.4.1
3.4.2
The Contractor's Q.C. Section shall liaise closely with the Employer's Representative
in charge of Quality Assurance/Quality Control, and to whom it shall fullest
cooperation. It is the underlying principle of this Contract document that while the
Contractor's Q.C. Engineer implements the Contractor's quality programme, the
adequacy and effectiveness of that implementation shall be audited by the Employer's
Representative at Site whose recommendations on improving or maintaining quality
shall be acted upon promptly by the Contractor's Q.C. Section.
3.5
3.5.1
WELDING MANUAL
3.5.1.1
3.5.1.2
The Manual shall cover in detail all the welding processes to be employed in this
project, their normal and special requirements and the quality controls to be
implemented.
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Furthermore, the part on Site welding shall incorporate as a minimum , all items
discussed in the Site Welding Documents and Site Welding Control.
3.5.2
3.5.2.1
Before commencement of Site Welding, the Contractor shall prepare the following
documents and submit to the Employer's Representative at Site for approval. In cases
where the Contractor employs Contracts to carry out certain Site Works, eg. nondestructive testings (NDT), it is still the Contractor's responsibility to prepare such
quality control documents relating to that Site Works. Furthermore, it is specifically
required in this Specification that such documents shall be, after the Contractor
obtains the necessary approval from the Employer's Representative, forwarded to the
Contracts for their compliance. It is the Contractor's responsibility to retrain, if
necessary, his Contracts's personnel and/or procure additional equipment in order to
meet the requirements of the approved quality control documents.
3.5.3
3.5.3.1
3.05.4
FABRICATION
3.5.4.1
3.5.4.1.1
(WPS)
AND
PROCEDURE
Weld procedures shall be designed to give a weld reinforcement height of 1.5 mm.
minimum to 3 mm. maximum.
The weld procedure documents shall be fully detailed and shall indicate clearly which
item it is intended to cover. The following information shall be included on each weld
procedure document:(1) The general arrangement drawing no, and identification of the weld
(2) Range of plate thickness or tube diameters covered by the procedure.
(3) Dimensioned details of weld preparation, the roof gap and the permitted
misalignment.
(4) Welding process for the roof run and for the filter material.
(5) The weld deposition procedure and the number of runs, including angle of
welding i.e. vertical, downhand overhead etc.
(6) Type of electrodes or wires and fluxes together with the maker's name, type
number and reference.
(7)
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(8)
(9)
Gauge of electrodes or wire to be used with the appropriate voltage and current
settings.
(10)
(11)
In the event of the Contractor wishing to make an alternation to any point of the
procedure, he is first to submit the Employers Representative a copy of the revised
procedure showing the amendment proposed and to await confirmation on its
acceptance or non-acceptance.
3.5.4.4
Approval of the welding procedure, etc., shall not relieve the Contractor of his
responsibility of quality work as per specification.
3.5.5
3.5.5.1
Materials
(3)
Filler materials
(4)
Pipe or plate
(5)
(6)
Positions
(7)
3.5.5.2
Each test procedure shall be specific in its details as to include, but not limited to,
information on specimen size, methods of tests : non-destructive and/or destructive,
assessment of test results, rejection and acceptance criteria.
3.5.5.3
The Contractor shall prepare weld maps of all the joints to be welded at Site. The weld
map shall show diagrammatically the location of each joint, the identification numbers of
the joints (each joint will have its own unique number), the dimensions and edge
preparation of each joint and the WPS applicable. The weld maps shall be submitted to
the Employer's Representative at Site for his comments and approval.
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3.5.6.1
Description
Specification
1.
Base metals
2.
406.4 x 67
(mm x mm)
3.
Welding
procedure
(WPS) no.
specification
55TA-SR1
4.
P-55TA-1
5.
6.
Root run
7.
Subsequent runs
8.
Preheat temperature ( C)
9.
10.
Soaking temperature ( C)
11.
168
12.
93
13.
50
14.
100%
15.
Non-destructive examination :
17.
Remarks :
Yes
3.5.7
NDT PROCEDURES
3.5.7.1
All NDT to be carried out at Site shall be approved procedures. Such procedures
shall not be just a reference to or a reproduction of agreed Standard, but shall be
tailor-made to take into account the actual works to be done at Site, the availability
and type of equipment at Site and the shall of NDT operators employed. The NDT
equipment shall be of well-known make and complies with the requirement of
approved Standards further all equipment should carry a calibration certificate.
3.5.7.2
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Not with standing any approval given to NDT operators of any Certification
Scheme, the Employer's Representative at Site has the right to conduct practical
tests involving actual construction items and/or test specimen as deemed fit by
him. Such tests shall be carried out by the Contractor at no extra cost to the
client.
3.5.8
3.5.8.1
For the purpose of this Clause, heat treatment includes post-fabrication heat
treatment of welds and post-heat treatment of welds. The Contractor shall
prepare the Heat Treatment Procedures based on agreed Codes and Standard
and/or Manufacturer's proven practice. The procedures shall not be just a
reference to or a reproduction of the agreed Standard, but shall be tailor-made to
suit the Site conditions : type of joints, accessibility, type and availability of
equipment at Site, and shall be suitable for the Heat treatment operation
employed.
3.5.8.2
Method(s) of heating
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
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(18)
(19)
(20)
3.5.9
REPAIRS
3.5.10
3.5.10.1
In order to monitor and maintain welding quality on Site, the Contractor shall
establish within his Site Organization an independent Quality Control Section,
whose function would solely to enforce the Contractor's field quality assurance
programme and Site Quality plans. Among areas where the Contractor shall
exercise greater controls, in order to achieve the desired quality, are control of
welders and control of welding activities, control of welding consumables and
control or NDT.
3.5.10.2
3.5.11
CONTROL OF WELDERS
3.5.11.1
The Contractor shall employ only experienced welders. However, all welders, with
or without previous qualifications, shall be tested to the approved Test
Procedures. Holders of current welding certificates from the Factories and
Machinery Department, Malaysia, shall not be exempted from sitting the test.
However, the Employer's Representative at Site may, at his discretion, allow these
welders to work if they can demonstrate their skill on five production joints, the
sizes and locations of them shall be selected by the Employer's Representative,
without any defects as revealed by visual inspection and radiography. The same
rule shall apply to bonafide welders from the Contractor's manufacturing works.
3.5.11.2
3.5.11.3
3.5.11.4
The Contractor shall monitor the performance of his welders throughout the
project. The Employer's Representative may require a welder to be re-qualified if
he deems the all of the welder has deteriorated, and the Contractor shall promptly
remove the said welder from the job.
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3.5.11.6
3.5.12
3.5.12.1
The Contractor shall at all times control its welding activities in a manner whereby
the quality requirement of its FQAP is never compromised, but at the same time
no delay to the welding progress is experienced. The Contractor shall draw up a
working procedure to accommodate the Employer's Representative at Site
participation in accordance with Table 1.
3.5.12.2
In all cases, the Contractor's scope shall be 100%. In cases where the
Employer's Representative participation is also 100%, such inspection may be
done jointly at the same time when the Contractor does his inspection. However,
the Employer's Representative may insist that the Contractor does his inspection
initially and correct whatever defects found before calling for the Employer's
Representative participation.
3.5.12.3
The Contractor shall liaise closely with the Employer's Representative and keep
him inform of the status of welding on hand. The Contractor shall submit a daily
return of welding works undicating the distribution of welders, the number and
identification of joints welded, the number and identifications of joints needed to be
NDT and PWHT.
3.5.12.4
The Contractor shall prepare all check sheets for the inspections, the format of
them shall be agreed with the Employer's Representative at Site. Such check
sheets must be signed by the relevant parties immediately at the end of each
inspection. The Contractor shall compile these check sheets and hand them in
bound volumes, appropriately titled, to the Employer's Representative at the end
of Site construction.
3.5.12.5
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Activities
1.
100% checking
2.
Cleaning of components
Spot checking
3.
Alignment of components
100% checking
4.
Fit-up checks
5.
Issue
of
material
6.
7.
8.
9.
PWHT
10.
11.
Hydrostatic Test
electrodes/filler
Spot checking
the
Employer's
Representative
3.5.13
3.5.13.1
3.5.13.2
3.5.13.3
The Contractor shall only bring to Site approved (as per the approved WPS)
welding electrodes and other filler materials.
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3.5.13.4
3.5.13.5
The Contractor shall provide electric ovens with suitable timers and temperature
indicators for the purpose of preheating the welding electrodes before issuing to
the welders. The quantity of electrodes issued shall only be sufficient for four
hours' use. The Contractors shall provide his welders with electrically heated
quivers to carry the electrodes to working areas. Furthermore, in order to ensure
compliance with the requirement that only four-hour use of electrodes are issued
at one time, the Contractor is required to provide two colour-coded quivers to each
welder, such that, for example, only red quivers are used in the morning and blue
ones in the afternoon (after lunch). It is strict requirement of this Specification that
the Contractor ensures that his welders return unused welding electrodes to store
after every four shift and fresh electrodes for use in the next four hours be issued
in different quivers.
3.5.13.6
The Contractor shall establish and follow diligently an Electrode Record Procedure
whereby the amount and type of electrodes issued to each welder at every issue
are recorded in either a Record Book or Card. Such record shall be made
available to the Employer's Representative at Site for scrutiny whenever
requested for.
3.5.13.7
For filler materials to be used in TIG welding process, the Contractor shall ensure
that the filler materials are clean, dry and rust-free. They shall also be positively
identified either by using tags, colour codings, or both. Alternatively, their
specification numbers shall be stamped on the rods at regular intervals in such a
manner that when cut in shorter lengths, such stamps will still be visible. For rods
that are identified by flags or colours, the Contractor shall also ensure that the
flags or coloursare also present in all lengths, when cut in shorter pieces. The
filler materials shall be carried to work-areas in suitable containers.
3.5.14
CONTROL OF NDT
3.5.14.1
The Contractor shall be responsible to control shall NDT activities under this
Contract, even when he Sub-Let-Contracts the job to a NDT specialist company.
3.5.14.2
He shall ensure that his NDT equipments are reliable, modern, calibrated and
comply with all relevant requirements of the agreed Standards.
3.5.14.3
The Contractor shall only employ mature and experienced NDT operators. He
shall ensure that the NDT operators hold current and relevant certificates from
approved Certification bodies such as National Industrial Training and Trade
Certification Board, Ministry of Labour, Malaysia. Not with standing such a
certificate, he shall promptly arrange for the demonstration of the skill of his NDT
operator to the Employer's Representative, should the Employer's Representative
may so request.
3.5.14.4
In the case of radiography, the Contractor shall comply with all the requirements of
the Act 304 of the Government of Malaysia - Atomic Energy Licensing Act 1984.
Radiographic (x-ray) works shall only be carried out after normal working hours,
from 7p.m. to 7a.m. the next day. However, the Employer his Representative may
delay permission to start radiography or suspend it for any duration during the
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If the Contractor desires to Sub-Let-Contract part or the whole of the NDT works
under his scope, he shall first obtain the approval from the Employer's
Representative at Site. He need to prove to the satisfaction of the Employer's
Representative that his quality of inspection will not be compromised even though
he Sub-Let-Contracts the inspection work.
3.5.14.6
The Contractor shall arrange for NDT works to be done promptly after completion
of welding, but in any case not later than 72 hours. Where welds require PWHT,
the NDT shall be done after the PWHT.
3.06
3.06.1
General
3.06.1.1
All equipment and components supplied shall be subjected to inspection and tests
by the Employers Representative during manufacture, erection/installation and
after completion. The inspection and test shall include but not be limited by the
requirements of this Contract document. Prior to inspection and testing, the
equipment shall undergo pre-service cleaning and protection.
3.06.2
3.06.2.1
The Contractor shall arrange for an independent third party certification to certify
the design, materials and construction of the equipment in his scope to comply
with design and statutory requirements and for insurance purposes. The
certification shall include all trade in the Contract Works and shall cover both
fabrication at the manufacturers works and at the Site.
3.06.2.2
The certification organisation shall be approved by, and registered with, the
Malaysian Factories and Machinery Department or relevant authorities and shall
be approved by the Employer. All costs associated with the third party certification
shall be borne by the Contractor.
3.06.3
Guarantees
3.6.3.1
Contractor shall state and guarantee the technical particular listed in the Schedule
of Technical Data. These guarantees and particulars shall be binding and shall
not be varied without the written permission of the Employers Representative.
3.6.3.2
3.06.4
Rejection
3.6.4.1
If the guaranteed performance of any item of equipment is not met and/or if any
item fails to comply with the specification requirement in any respect whatsoever
at any stage of manufacture, test or erection, the Employers Representative may
reject the item, or defective component thereof, whichever he considers
necessary, and after adjustment or modification as directed by the Employers
Representative, the Contractor shall submit the item for further inspection and/or
test.
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All repair procedures shall not be performed without the prior approval of the
Employers Representative. In the event of a defect on any item being of such a
nature that the specification requirements cannot be fulfilled by adjustment or
modification, such item shall be replaced by the Contractor, at his own expense to
the entire satisfaction of the Employers Representative. Any item repaired to an
approved procedure shall not be accepted as a part of the Works as a permanent
solution or replacement unless the Contractor guarantees in writing that the
repaired component shall have the same service life and efficiency as the
component originally manufactured.
3.6.4.3
The approval of the Employers Representative of inspection and/or test results will
not prejudice the right of the Employers Representative to reject an item of
equipment if it does not comply with the Contract document when erected or
prove completely satisfactory in service.
3.06.5
Contracts
3.6.5.1
The Contractor shall be responsible for the timely transmission of the relevant and
appropriate sections of the Contract document to Contracts and other
manufacturers and the proper execution of all tests on work materials carried out
or supplied by Contracts, wherever such tests may be carried out, to the same
extent as if the tests on work, materials were carried out or supplied by the
Contractor himself.
3.07
3.7.1
Steel Castings
3.7.1.1
The Contractor shall prepare materials purchasing specifications for all important
castings.
Each document shall indicate fully the quality and inspection
requirements for the component casting covered. Copied of this Specification
shall be issued to the Employers Representative for his use. Wherever possible
castings shall be selected from the range of materials covered in the ANSI, ASME
or ASTM Standards and the inspection and quality requirements together with the
other provisions of this Specification shall be regarded as the minimum acceptable
Standard.
3.7.1.2
3.7.1.3
Magnetic particle inspection shall be applied to all castings after acid cleaning and
shot blasting. All defect cut outs shall be inspected by magnetic particle
inspection after grinding and before repairs are commenced.
3.7.1.4
3.7.1.5
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3.7.1.7
Selected areas for future butt welds shall be subjected to radiographic (x-ray)
examination. The defects revealed by this examination shall be compared with
the acceptance criteria given within the agreed standard. Wherever possible the
acceptance criteria shall be related to an agreed set of reference radiographs.
The reference radiographs to be used for this purpose together with the selection
of the standard films for shrinkage, subsurface linear discontinuities, porosity,
voids, sand and slag shall be to the Employers Representatives approval.
3.7.1.8
3.7.1.9
3.7.1.10
All castings shall be identified by hard stamped, or cast on reference marks which
shall be entered on all relevant documents and test certificates.
3.07.2
3.7.2.1
3.7.2.2
Test blocks are to be integrally cast on all medium and large castings.
3.7.2.3
The Employers Representative may require that certain castings shall be checked
using radiographic (x-ray) techniques. The Contractor shall include for this eventually
and shall comply with the Employers Representatives instruction when issued.
3.07.3
3.7.3.1
The Contractor shall prepare material purchasing specification for all important
aluminium bronze castings. Each document shall indicate fully the quality and
inspection requirements for the component casting covered.
Copies of the
specification shall be issued to the Employers Representative for his use. The
inspection and quality requirements shall include chemical analysis of each cast,
mechanical testing of tests bars for each cast, pressure testing, penetrant flow
detection and radiographic (x-ray) examination of selected critical areas.
3.7.3.2
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Steel Forgings
3.07.4.1
The Contractor shall draw up material purchase specifications for all important
forgings, and supply copies of these specifications to the Employers Representative
for his use. Specifications shall be produced for, but not limited to compressor shafts,
motor shafts and precision forge compressor blades, etc. In each case the quality and
inspection requirements shall be clearly stated.
3.7.4.2
Sulphur prints shall be taken from all large forgings and other forgings as directed by
the Employers Representative, the prints shall indicate the absence of significant
segregation.
3.7.4.3
Test blocks from which the mechanical test pieces will be machined shall be cut from
the forgings at positions to be agreed by the Employers Representative. On large and
important forgings several test pieces shall be taken from radial and longitudinal
directions.
3.7.4.4
Solid shaft forgings will be acceptable provided that ultrasonic examination confirms
the absence of centre line defects. The Employers Representative will reserve the
right to insist that shaft or rotor forgings with centre line defects shall be bored to
remove such defects.
3.7.4.5
Shaft and rotor bores where provided, shall be smooth machined to a standard
suitable for intrascope examination. Trepanned sections of the cores shall be
subjected to mechanical test for information purposes only. Local chamfering or
remachining of bores to a larger diameter shall only be carried out with the approval of
the Employers Representative.
3.7.4.6
Bores, where provided, shall be inspected visually and with magnetic particle
inspection. Magnetisation shall be in accordance with the ANSI, ASME or ASTM
Standards. The inspection shall be made with a suitable intrascope having an
acceptable level of illumination and magnification.
3.7.4.7
Bearing journals of large shafts and rotors shall be subjected to dye penetrant
examination on completion of final machining.
3.7.4.8
Repairs by welding or other means shall not be undertaken on forgings at any stage of
the production cycle.
3.7.4.9
3.7.4.11
Each forging shall be suitably branded with an identification number which shall be
transferred throughout all final machining stages. The identification number shall be
marked on all documents and test certificates relative to the forging.
3.7.4.12
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3.8.1
GENERAL
3.8.1.1
Where no specific test is specified then the various items of materials and equipment
shall be tested in accordance with the specifications. Where no appropriate Standard
is available, tests shall be carried out in accordance with the manufacturers Standard
practice, subject to the prior approval of the Employers Representative. In all cases,
works tests shall include electrical, mechanical and hydraulic tests in addition to any
test called for by the Employers Representative to ensure that the equipment being
supplied fulfils the requirements of the Contract document. Where applicable, tests
must comply with the requirements of the Factories and Machinery Regulations 1970,
of the Government of Malaysia.
3.8.1.2
3.8.1.3
3.8.1.4
3.8.1.5
No. plant shall be packed, prepared for shipment, or dismantled for the purpose of
packing for shipment, unless it has been satisfactorily inspected, all tests called for
have been successfully carried out in the presence of the Employers Representative
or approved for shipment, or alternatively inspection has been waived.
3.8.1.6
Functional electrical, mechanical and hydraulic tests shall be carried out on completed
assemblies in the works. The extent of these tests and method of recording the
results shall be submitted to, and agreed by, the Employers Representative in
sufficient time to enable the tests to be satisfactory witnessed, or if necessary for any
changes required to the proposed programme of tests to be agreed.
3.8.1.7
All instruments and apparatus used in the performance of the tests shall be supplied
by the Contractor, to the approval of the Employers Representative and shall be
calibrated to an agreed Standard at SIRIM (Malaysia), or equivalent centres approved
by the Employers Representative. Calibration Tests Certificates shall be submitted in
respect of each and every instrument and apparatus. All calibration shall be conducted
within 6 months before the date of the actual tests and the corresponding tests
certificates shall be issued and submitted to the Employers Representative at least 1
month before commencement of the test. Calibration done and Certificates issued
outside the period aforementioned shall not be valid and the Contractor shall arrange
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The Employers Representative reserves the right to visit the Manufacturers Works at
any reasonable time during fabrication of equipment and to familiarize himself with the
progress made and the quality of the work to date.
3.8.2
MATERIAL TESTS
3.8.2.1
Representative samples of all plates, bars and pipe, etc., which form components of
the equipment shall be tested as required by the relevant approved Standard. All test
precious shall be prepared and supplied by the Contractor at his own cost. If any test
piece fails to comply with the requirements of the specifications for the material in
question, the Employers Representative may reject the whole of the material
represented by that test piece.
3.8.3
TEST CERTIFICATES
3.8.3.1
Within 30 days of the completion of any test, triplicate sets of all principal test records,
test certificates and correction and performance curves shall be supplied to the
Employers Representative.
3.8.3.2
These test records, certificates and performance curves shall be supplied for all tests,
whether or not they have been witnessed by the Employers Representative or not.
The information given on such test certificates and curves shall be sufficient to identify
the material or equipment to which the certificate refers and should also bear the
Contract reference title.
3.8.3.3
When all equipment has been tested, the test certificates from all works and site tests
shall be complied by the Contractor into volumes and bound in an approved form
complete with index and four copies of each volume shall be supplied to the
Employers Representative.
3.9
TYPE TESTS
3.9.1
Type tests are required on all equipment whether specifically noted or not to prove the
general design the equipment in accordance with the relevant approved Standards
and the Contractor may submit test certificates of tests which have been carried out on
identical equipment. Notwithstanding any provision in a Standard, the employers
Representative shall have the right to accept or reject such certificates in lieu of the
specified type tests.
3.9.2
The type tests prescribed shall be carried out at the Contractors cost in all cases
where such certificates are not available or are rejected.
3.9.3
Notwithstanding the above one type of each rating of equipment shall be type tested
under this Contract, to the relevant approved Standard, and test certificates submitted
to the Employers Representative.
3.10
ROUTINE TESTS
3.10.1
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HYDROSTATIC TESTS
3.11.1
All cast, forged of fabricated pressure vessels or enclosures and all completed pipes,
bends and fittings which are to be subjected to an internal pressure or vacuum during
operation shall be subjected in the makers works to a hydrostatic test. The test
pressure shall be maintained for a minimum of 30 minutes or longer at the discretion
of the Employers Representative to permit complete examination by the Inspector.
3.11.2
All hydrostatic tests shall be carried out prior to surface coating or painting and cast
iron enclosures may be subjected to hammering as required by the Employers
Representative.
3.11.3
3.11.4
The manufacturer shall supply labour and appliances for such testing as may be
carried out on his premises. Failing facilities at his own works the manufacturer shall
make arrangements for carrying out the tests elsewhere.
3.11.5
The testing shall include, but not be limited to, the following system :-
3.11.5.1
Each sections of the compressor casing, control valves and emergency stop valves
shall be tested as defined in the relevant Standard for a minimum of 2 hours duration.
3.11.5.2
Pipework shall be hydrostatically tested in accordance with the relevant Standard. The
test pressure shall not be less than one and one half times the normal working
pressure. Any expansion bellow shall be tested together with an adjacent section of
pie. Satisfactory arrangements must be made to protect the bellows from damage
during the test.
3.11.5.3
The body of each valve of fitting shall be tested to not less than one and on half times
its design pressure. In the particular case of safety valves the seats shall be blanked
and the hydrostatic pressure applied only the part of the body at the inlet valve.
3.11.5.4
With the exception of the following items and items which may suffer internal damage
e.g. bellows operated instruments, etc., each assembled fitting shall be tested to not
less than one and one half times its design pressure.
1) Assembled safety valves
2) Tubular glasses for water gauges
3) Sub-assemblies containing the glasses of water gauges of the through vision or
reflex glass type.
3.11.5.5
Pressure gauges shall be tested in accordance with the relevant approved Standard.
3.11.5.6
3.11.5.7
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3.12.1
3.12.2
Each equipment shall be subjected to a performance test to prove that reliability and
operation and performance conform to the requirements of this Specification.
Equipment shall be fully assembled and complete in every respect prior to the
commencement of Works performance tests. The Contractor, at his own expenses,
he will arrange for one representative each from the Employer Representative, the
Employer's organization and the design consultant to witness this performance test.
3.12.3
Pumps, fans compressors and other rotating equipment shall be given full load tests,
and run to 15% over speed for 5 minutes to check vibration. Main and auxiliary gear
boxes shall be subjected to shock load test and a six-hour endurance run at rated
speed and maximum torque.
3.12.4
The Contractor shall submit single line diagrams including the location of test
instrumentation and the principal dimensions of the layout. All calculations to device
performance data shall be made strictly in accordance with formulae given in the
approved Standards. Any alterations or deviations from the approved test layout or
formulae shall be subjected to the prior approval of the Employers Representative.
3.12.5
The formulae used for correcting test results to Site conditions shall be subjected to
the Employers approval and be given with the test results together with calibration
details of any measuring instruments.
3.12.6
All pressure gauges, flow meters, venturi tubes or ducts, office plates and other
instruments to be used for works tests shall be subjects to routine calibration against
Standard instruments. Calibration records shall be available for inspection by the
Employers Representative.
3.12.7
Wherever possible, equipment shall be tested with the driving motor specifically
purchased for the respective item. Where such an arrangement is not practical then it
will be permissible to utilize a test motor providing fully technical performance details
are available for scrutiny by the Employers Representative.
3.12.8
The Contractor shall demonstrate that the system under this Contract is of a
satisfactory proven type in commercial operation. In such a case, at his own expense,
he will arrange for one representative each from both the Employers Representative
and the Employers organization to visit such units and to meet with responsible
representative of the respective owners/operators.
3.12.9
Each completed rotating units shall be subjected to a dynamic balance test. A check
balance test shall be carried out after the item has been subjected to any overspeed or
performance test. The Standards for dynamic balance shall be specified by the
manufacturer and agreed by the Employers Representative.
3.12.10
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The performance test shall be conducted over the fully operating range of the pump to
a closed valve condition and a minimum of five measurement points covering the full
range shall be taken. Curves indicating Quantity vs. Head, Quantity vs. Power
absorbed, and Quantity vs. Pump efficiency shall be provided. In addition a curve of
the NPSH required vs. Quantity shall be provided except when the suction conditions
do not require this test. Any proposal for the omission of this test shall be to the
approval of the Employers Representative.
3.12.12
On completion of tests the Contractor shall submit a report showing the rest results
obtained together with the curves corrected to the Site operating conditions.
3.12.13
The Contractor is to state his normal practice with regard to the testing of turbine
components, the trial erection of the turbine, and the steaming of the turbine assembly
in works to prove the satisfactory mechanical operation prior to despatch to Site.
3.12.14
Air compressors shall be tested in accordance with the requirements of the relevant
Standard and the particular test procedure to be applied to each compressor shall be
agreed with the Employers Representative.
3.12.15
All inspection, testing, marking and certification for Air Receivers shall be performed to
the appropriate ANSI, ASTM and ASME Standards.
3.12.16
The vessels shall be constructed and tested under the supervision of a third party
inspector approved by the Employers Representative.
Safety valves, bursting discs and other fittings shall be tested in accordance with the
requirements of the appropriate ANSI, ASTM, ASME Standards.
3.12.17
The Contractor shall carry out at this Works, tests as required by the ANSI, ASTM and
ASME Standards, to prove the capacities of the lifting equipment Test Certificates
shall be provided and shall include the material of fabrication, welding and nondestructive testing, electrical equipment, wire ropes, hooks, chain blocks, shackles,
runway beam, eye bolts and any other related items which are provided.
3.12.18
All tests shall be carried out in the presence of the Employers Representative and the
nominated third party inspector. Upon completion of the tests, the equipment shall be
clearly marked with the equipments safe working load (SWL) and any making that the
Employers Representative may require. A permanent nameplate shall be attached
containing the following information :Date of manufacture
Date of test
Load applied
3.12.19
3.13
3.13.1
The testing of storage tanks shall conform to the appropriate ASME and ANSI
Standard.
ACCEPTANCE TESTS OF ELECTRICAL EQUIPMENT
Acceptance tests shall be carried out by random sampling of manufactured
equipment in accordance with IEC. The results of tests shall be recorded and verified
by the Employers Representative. Three copies of the test result shall be submitted to
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3.14.1
During the course of erection, the Employers Representative shall have full access for
inspecting the progress of the work and checking its accuracy by witnessing such
checks as may be required by him.
3.14.2
The Contractor shall provide all temporary scaffolding, platforms with adequate and
safe flooring and handrails essential for proper access of the Employers
Representative to carry out inspection.
The Contractor shall provide all labour, materials and instruments and other resources
necessary for the use of the Employers Representative for checking, setting out of the
Works, for the periodic measurement of the works executed and for the
aforementioned Site inspections and tests.
3.14.3
3.14.4
3.14.5
The Contractor shall provide all erection check lists for the works, copies of which are
to be provided to the Employers Representative after signing at each stage of
inspection.
3.14.6
The Contractor shall record the results of the tests clearly, on an approved form and
with clear reference to the equipment and items to which they refer, so that record can
be used as the basis for maintenance tests by the Purchaser during the working life of
the equipment. The required number of site test result records shall be provided by the
Contractor to the Engineer as soon as possible after completion of the tests. This
information is required by E.R. before the system will be accepted for initial energizing.
3.14.7
No tests as agreed under the programme of tests shall be waived except upon the
instruction or agreement of the Employers Representative in writing.
3.14.8
The Contractor shall submit to the Employers Representative for his approval a list of
recommended settings for all protection and other types of automatic equipment, not
less then three (3) months before such equipment is required in service. Where the
settings involve discrimination with settings of TNBs network, the relevant information
shall be supplied to the Contractor.
3.14.9
The Contractors test equipment shall be of satisfactory quality and condition and shall
be appropriately calibrated by and approved authority or standard at the Contractors
expense. Details of the test equipment and instruments used shall be noted in the test
sheets in cases where the instrument or equipment characteristics can have a bearing
on the test results.
3.15
TESTS AT SITE
3.15.1
GENERAL
3.15.1.1
All equipment and assemblies shall pass site tests to prove compliance with the
Contract document independently of any tests which may have already been carried
out at the Manufacturers Works.
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The Contractor shall check electrical and mechanical connections to all equipment and
assemblies supplied under the Contract before they are brought into commission and
shall be responsible for the correctness of such connections in accordance with the
Contract document.
3.15.1.3
In particular all functional and pressure tests on fully assembled and complete items of
equipment and assemblies which have not been carried out at the manufacturers
works, shall be carried out at Site.
3.15.1.4
All instruments and apparatus used in the performance of the tests shall be supplied
by the Contractor and shall be to the approval of the Employers Representative and
shall be calibrated to an approved Standard at SIRIM (Malaysia) or equivalent centres
approved by the Employers Representative. Calibration Tests Certificates shall be
submitted in respect of each and every instrument and apparatus. All calibration shall
be conducted within 6 months before the date of the actual tests and the
corresponding tests certificates shall be issued and submitted to the Employers
Representative at least 1 month before commencement of the test. Calibration done
and Certificates issued outside the period aforementioned shall not be valid and the
Contractor shall arrange for the recalibration of the instrument or apparatus at no extra
costs to the Employers Representative.
3.15.1.5
3.15.1.6
The Contractor shall submit a written programme of tests and checks for the approval
of the Employers Representative.
3.15.1.7
The Contractor shall provide experienced test personnel subject to the approval by the
Employers Representative (CVs shall be submitted) and conditions imposed by the
Electrical Supply Regulations issued by the Department of Electricity Supply, Ministry
of Energy, Telecommunication and Post Malaysia, and any regulations ruling at that
time on such practice
3.15.1.8
The testing shall be carried out during normal working hours as far as is practicable.
3.15.1.9
The Contractor shall advise the Employers Representative in writing at the time of
commencement of site erection of the site supplies which will be required for the
operation of the test equipment.
3.15.2
HYDROSTATIC TESTS
3.15.3
After erection a hydraulic test shall be carried out on each heat exchanger with all
mountings, fittings and associated piping in compliance with the relevant Standard
approved by the Employers Representative and with the Malaysian Factories and
Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970, with all
fittings and mountings in position. No control valve shall be used as a block valve for
the purpose of this or any other test.
3.15.4
PIPEWORK TESTING
3.15.5
PRELIMINARIES
3.15.5.1
The Contractor shall be responsible for conducting pressure tests but these shall be
witnessed by the Employers Representative to his satisfaction and approval.
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On completion of erection, the interior of all pipes, valves, fittings and other associated
equipment shall be flushed and free from loose mill scale, welding slag, temporary
protective coating and other foreign matter.
3.15.5.3
Mechanical equipment and pressure relieving devices shall be blanked off or removed
from the line during pressure testing.
3.15.5.4
3.15.5.5
Instruments, filters and similar equipment for which the maximum permissible cold test
pressure is lower than the test pressure applied to the system, shall be removed or
blanked off or removed from the line before testing. Such equipment shall be
inspected during commissioning.
3.15.5.6
Provision shall be made for the automatic relief of excess pressure caused by thermal
expansion.
3.15.6
HYDROSTATIC TESTING
3.15.6.1
The completed piping system shall be tested to a pressure of at least one and one half
times the design pressure.
3.15.6.2
The test pressure shall be maintained for a period of at least 24 hours. After correction
for variation caused by temperature changes, the initial and final test readings shall
not differ by more than 5%. Four reading shall be recorded.
3.15.6.3
Temporary vents shall be located at high points in the system or section thereof to be
tested, in order to ensure complete displacement of air.
All testing equipment such as temporary pumps, strainers, pipework, valves,
instrumentation etc. shall be included under this Contract.
3.15.6.4
3.15.7
REPEAT TESTING
3.15.7.1
Upon failure of the pressure test results to meet the above requirements the
Contractor shall check the installation for leaks and other defects and carry out
rectification work accordingly to the satisfaction of the Employers Representative. He
shall fully inform the Employer' Representative of all reticulation works. The pressure
test shall then be repeated. This procedure shall be repeated until satisfactory results
are obtained. The Employers Representative may, at his discretion, review the test
requirements in accordance with Site conditions.
3.15.8
WELDED PIPEWORK
3.15.8.1
All chilled water service pipe for both above and below grade shall have all their welds
inspected using ultrasonic tested or dye-penetration. In addition, 10% of the total welds
shall be radiographed to ASME B31.1 standards to ensure weld integrity, visually
inspected and signed off by ER. When one or more failures occur in a sampling
examination, for example in 10% radiography, than the failure(s) shall be repaired and
re-radiographed, and a further 10% radiography sampling is to be taken. If there is
further failure(s), the new failure(s) shall be repaired and re-radiographed, and
additionally now, all the remaining unexamined welds shall be radiographed and
repaired, if necessary, and re-radiographed until all the welds are confirmed to be
without defects. All below grade piping shall be visually inspected using a camera which
can be routed through the pipeline.
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TESTING REQUIREMENTS
3.15.8.3
All chilled water service pipe for both above and below grade shall have all their welds
inspected using ultrasonic tested or dye-penetration. In addition, 10% of the total welds
shall be radiographed to ASME B31.1 standards to ensure weld integrity, visually
inspected and signed off by ER. When one or more failures occur in a sampling
examination, for example in 10% radiography, than the failure(s) shall be repaired and
re-radiographed, and a further 10% radiography sampling is to be taken. If there is
further failure(s), the new failure(s) shall be repaired and re-radiographed, and
additionally now, all the remaining unexamined welds shall be radiographed and
repaired, if necessary, and re-radiographed until all the welds are confirmed to be
without defects. All below grade piping shall be visually inspected using a camera which
can be routed through the pipeline.
3.15.9
AIR PIPING
3.15.9.1
All air piping before being concealed and before acceptance of the work shall be
subjected to an air tests of one and half times its design pressure but not less than 4.5
bar g and all joints shall be checked for leaks using a soap solution test. Tests shall be
made for a period of two hours.
3.15.9.2
All compressed lines shall be blown though with compressed air before connection is
made to instruments and other equipment.
3.16
3.19.1
GENERAL
A short description of the various inspection methods is included in this specification to
provide a reference base for both the Contractor and the Inspector in order to ensure
that all coating related activities and the final coating film conform to the requirements
as laid in this specification.
These inspection procedures shall be used singly or in conjunction with each other
as circumstances may warrant to resolve disputes relative to application conditions,
film, thickness, degree of cure, adhesion to the substrate or between coats,
determination of the correct time between coats etc. and to determine whether
individual coating films or the total coating system meet the acceptance criteria
specified.
3.19.2
3.19.2.1
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3.19.2.3
3.19.2.4
HARDNESS TESTING
3.19.2.4.1 The Barcol Hardness Gauge No. 935 or similar shall be used to determine the degree
of cure of Ultra High Build (UHB) coatings. The measurements shall be carried out by
placing the gauge on an area of smooth coating surface (free of overspray or orange
peel), pressing the needle into the surface and noting the highest value reached on
the dial.
To determine whether the curing process is progressing satisfactorily all areas of
freshly applied coating shall be tested for hardness 6 to 24 hours after application
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ii)
The coating shall be checked for hardness over next 72 hours to clearly established a
hardening trend. Coating not showing a satisfactory trend shall be rejected and
replaced.
The coating shall be considered fully cured when the Barcol rating is in the range of:-
i) 70-75 for epoxies 7 days after application (@ 24C and 30-60%RH); and
ii)
80-90 for polyesters, 7 days after application (@ 8-25% and 50-80% RH)
3.19.2.4.2 The Dur-O-Test Hardness Tester shall be used to determine the degree of cure mainly
of inorganic zinc silicate films but may also be used in the case of thin film catalyzed
coatings. The procedure for use is as follows :In the pretensioned state, the scratch needle extends slightly out of the jacket. The tip
of the DUR-O-TEST shall be placed on the coating surface (ensuring that it is square
on the surface) and a line shall be drawn approximately 25 mm long within three
seconds, maintaining sufficient pressure to keep the needle against the rod stop. If the
tension has been too high, the surface will be clearly marked if too low, there will be no
mark. The correct pretension will result in a barely visible mark - this is the pretension
that should be reported as value P. In the case of inorganic zinc silicates, the P
value to be reported will be the one at which, when the line is drawn, then will be no
accumulation of zinc dust at the end of the line. The interchangeable springs of
varying strengths correspond to test ranges engraved as scales on the jacket of the
instrument.
No. 1:0 300P (Division = 10P, Plain Spring)
No. 2:0 1000P (Division = 50P, Red Spring)
No. 3:0 2000P (Division = 100P, Blue Spring)
Inorganic zinc silicate coatings, should have a minimum hardness of 250 P, before
they may be top coated. Depending on the prevailing conditions, this value of
hardness can be attained within four to 24 hours after application with both the he
solvent and water home inorganic zinc silicate coatings. A hardness of 200 to 240 P
shall be accepted but only if a trend of hardening has been clearly established over a
period of not less than 72 hours after application.
Note
3.19.2.5
ADHESION TESTS
The test may be used to determine the bond of single coating films (including
inorganic zinc silicates) to the substrate as well as the adhesive and cohesive stretch
of multicoat systems.
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20 kg/cm2 minimum in the case of inorganic zinc silicate / epoxy topcoat systems.
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Surface Condition
The metal surfaces shall be clean and free of mill scale, rust, dirt, grease and any
other deleterious matter.
Where metal surfaces are to be painted the surface profiles shall conform with the
painting specification requirements.
Where this does not apply, surfaces shall have a surface texture not coarser than
Grade 80 abrasive paper.
3.20.2.2
Abrasives
Abrasives containing silica, silicates or slag residues shall not be used for water
/steam side surfaces of plant except for cleaning sand castings where hydro-blasting
with sand may be used.
For austenitic materials only abrasives containing 98% or more of alumina A1 2 03 shall
be used.
3.20.2.3
3.20.2.4
3.20.2.5
General
The procedure shall comprise pre-treatment, acid treatment, neutralization, rinsing and
drying to achieve cleanliness equivalent to that specified for mechanical cleaning. The
procedure to be adopted shall be to the Employers Representative approval.
4.0
EXECUTION
1.1 TESTING
.1 GENERAL
.1 Perform all tests required by Codes, Ordinances, and as specified herein, as
well as demonstrations of operation for all equipment. Each final test to be
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3.20.3
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3.20.3.1
3.20.3.2
General
In interpreting the following requirements, no items incorporating copper or aluminium
or their alloys, or zinc coatings shall undergo any chemical cleaning other than
flushing or manual cleaning as agreed with the Employers Representative.
The Contractor shall take all necessary precautions to ensure that the internal
surfaces of all site are kept clean and free from injurious matter during erection.
When the site has been erected and lagged or at such other time as may be agreed
with the Employers Representative for sub-assemblies, the installation shall undergo
a procedure for Site cleaning in accordance with the requirements and associated
Schedules as specified herein.
All switchboards, panel boards, wireways, enclosures, etc. to be thoroughly vacuum
cleaned prior to energizing equipment and at the completion of the project. Equipment
shall be opened for observation by the Employer's Representative as required.
3.20.3.3
3.20.3.4
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3.20.4 INSPECTION
At the end of the cleaning operations, the Site shall be made available for inspection.
In event that the surfaces are not cleaned to the Employers Representative satisfaction
such parts of the cleaning procedure or agreed alternatives as are deemed necessary to
overcome the deficiencies shall be carried out at the Contractors sole expense.
3.20.5 PROGRAMME FOR SITE CLEANING
At an appropriate time not less than six months prior to commencement of any Site
cleaning, the Contractor shall submit a detailed site cleaning specifications and
programme including procedure details, supporting calculations giving cleaning times,
velocities, chemical solutions, silencing, drag factors, pipework forces and moments
imposed during site cleaning operations.
3.20.6 DISPOSAL OF WASTE EFFLUENTS AT SITE
The Contractor will be responsible for satisfactorily disposing of all waste effluent liquors
and materials and treating them to render them suitable for discharge to waste in
accordance with regulations prevailing at Site regarding disposal of waste effluents.
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Commissioning_MECH.odt